Cushion backed carpet

Abstract

An improved cushioned carpet fabric is provided. The cushioned carpet comprises a primary carpet having a primary base and a plurality of pile-forming yarns projecting outwardly from one side. A layer of reinforcement material is bonded to the primary base on the side opposite the pile forming yarns. The reinforcement layer is adjacent to and embedded in, a cushion layer of a polymer such as a polyurethane. There is preferably no additional adhesive between the cushion layer and the layer of reinforcement material since the primary carpet fabric is mated in-situ to the polyurethane-forming composition without preheating the polyurethane-forming composition. An apparatus and process for forming the cushioned carpet fabric of the present invention are also provided.

What is claimed is:  
     
       1. A dimensionally stable cushioned carpet tile suitable for disposition as discrete modular units across a flooring surface, the carpet tile comprising: a stabilized composite structure bonded to an underlying foamed cushion layer of polyurethane wherein said stabilized composite is comprised of; 
       (i) a primary carpet fabric having a pile side and an underside with a plurality of pile forming yarns projecting outwardly from said pile side,  
       (ii) an adhesive layer consisting essentially of at least one resilient adhesive directly bonded to and extending away from the underside of said primary carpet fabric, and  
       (iii) a layer of stabilizing material in contacting relationship with said resilient adhesive such that said layer of stabilizing material is held in place at a fixed position below said primary carpet fabric,  
       said foamed cushion layer having been cured in contact with said layer of stabilizing material such that said foamed cushion layer is bonded to said stabilized composite structure and at least a portion of said layer of stabilizing material extends below the surface of said foamed cushion layer thereby being embedded within said foamed cushion layer. 
     
     
       2. The carpet tile as in claim  1 , wherein said foamed cushion layer is comprised of a mechanically frothed polyurethane foam. 
     
     
       3. The carpet tile as in claim  2 , wherein said polyurethane foam has cured density of greater than about 10 lbs/ft 3 . 
     
     
       4. The carpet tile as in claim  1 , further including a layer of backing material disposed adjacent to the surface of said foamed cushion layer facing away from said stabilized composite structure. 
     
     
       5. The carpet tile as in claim  4 , wherein said backing material is a woven textile product. 
     
     
       6. The carpet tile as in claim  5  wherein the materials forming a said woven textile product are selected from the group consisting of polyester, polypropylene, nylon, fiberglass and blends thereof. 
     
     
       7. The carpet tile as in claim  4 , wherein said backing material is a nonwoven textile product. 
     
     
       8. The carpet tile as in claim  7 , wherein the materials forming said nonwoven textile product are selected from the group consisting of polyester, polypropylene, nylon, fiberglass and blends thereof. 
     
     
       9. The carpet tile as in claim  1 , wherein said stabilizing material is selected from the group consisting of nonwoven glass and woven glass. 
     
     
       10. The carpet tile as in claim  1 , wherein said resilient adhesive is a hot melt adhesive. 
     
     
       11. The carpet tile as in claim  1 , wherein said stabilizing material is selected from the group consisting of woven polyester, and nonwoven polyester. 
     
     
       12. A cushioned carpet tile suitable for disposition as discrete modular units across a flooring surface, the carpet tile comprising: 
       a primary carpet fabric having a pile side and an underside and having a plurality of pile forming yarns projecting outwardly from the pile side;  
       an adhesive layer consisting essentially of at least one adhesive directly bonded to and extending away from the underside of said primary carpet fabric;  
       a layer of stabilizing material in contacting relationship with said adhesive such that said layer of stabilizing material is held in place by said adhesive at a fixed position below said underside of said primary carpet fabric so as to provide dimensional stability to said carpet tile;  
       a cured foam cushion layer of polyurethane disposed adjacent to said stabilizing material, said foam having been cured in contact with said stabilizing material so as to provide a contact surface for said foam such that said stabilizing material is at least partially embedded in and bonded to said cured foam; and  
       a textile backing material disposed adjacent to the surface of said foam cushion layer facing away from said stabilizing material.  
     
     
       13. The carpet tile as in claim  12 , wherein said foamed cushion layer is comprised of a mechanically frothed polyurethane foam. 
     
     
       14. The carpet tile as in claim  13 , wherein said foamed cushion layer has a cured density of greater than about 10 lbs/ft 3 . 
     
     
       15. The carpet tile as in claim  14 , wherein said foamed cushion layer has a cured density of about 12 lbs/ft 3  to about 18 lbs/ft 3 . 
     
     
       16. The carpet tile as in claim  12 , wherein said textile backing material is a woven product. 
     
     
       17. The carpet tile as in claim  16  wherein the materials forming said woven textile product are selected from the group consisting of polyester, polypropylene, nylon, fiberglass and blends thereof. 
     
     
       18. The carpet tile as in claim  12 , wherein said textile backing material is a nonwoven product. 
     
     
       19. The carpet tile as in claim  18 , wherein the materials forming said nonwoven textile product are selected from the group consisting of polyester, polypropylene, nylon, fiberglass and blends thereof. 
     
     
       20. A cushioned carpet tile suitable for disposition as discrete modular units across a flooring surface, the carpet tile comprising: 
       a primary carpet fabric having a pile side and an underside and having a plurality of pile forming yarns projecting outwardly from the pile side;  
       an adhesive layer consisting essential of at least one adhesive directly bonded to and extending away from the underside of said primary carpet fabric;  
       a layer of glass stabilizing material in contacting relationship with said adhesive such that said layer of glass stabilizing material is held in place by said adhesive at a fixed position below said underside of said primary carpet so as to provide dimensional stability to said carpet tile;  
       a cured foam cushion layer of mechanically frothed polyurethane disposed adjacent to said stabilizing material, said foam having been cured in contact with said stabilizing material which provides a contact surface for said foam such that said stabilizing material is at least partially embedded in and bonded to said cured foam; and  
       a woven textile backing material selected from the group consisting of polyester, polypropylene and blends thereof disposed adjacent to the surface of said foam cushion layer facing away from said stabilizing material.